Abstract
The surface layer states of a component are of great importance for the application of hard turned parts. Without a multitude of tests and experience, the states cannot be reliably produced due to process-typical disturbance variables such as tool wear and batch inclusions. The aim of this research is to control the surface layer states during cryogenic hard turning of AISI 52100 by feedforward control and the use of a soft sensor. This paper presents the measurement techniques used in this context. On the one hand, the in-process measurement technology and challenges involved are discussed. On the other hand, the challenges in the ex-situ measurement technique for characterizing the surface layer states are shown using micro hardness measurement as an example.
Zusammenfassung
Die Funktionseigenschaften eines Bauteils werden maßgeblich von dem Randschichtzustand bestimmt. Da das Einstellen dieses Zustands im Endbearbeitungsprozess von prozesstypischen Störgrößen, wie beispielsweise dem Werkzeugverschleiß und Chargeneinflüssen beeinflusst wird, können diese Eigenschaften nur durch Iterationsschleifen in Verbindung mit Erfahrung erzeugt werden. Ziel der Forschung ist es, die Randschichtzustände beim kryogenen Hartdrehen von 100Cr6 durch eine Vorsteuerung in Verbindung mit einem Softsensor zu überwachen und gezielt einzustellen. Das vorliegende Paper geht in diesem Kontext auf die verwendete Messtechnik ein: zunächst auf die In-process-Messtechnik und die damit verbundenen Herausforderungen, anschließend auf die Schwierigkeiten bei der Charakterisierung des Randschichtzustands am Beispiel der Mikrohärtemessung.
About the authors
Julian Uebel completed his mechanical engineering studies at the University of Kaiserslautern in 2017 and has been Research Assistant at the Institute for Measurement and Sensor Technology since then. Since 2018 he is working on a subproject of the Research Priority Program 2086 of DFG. The research focus is on optical and pneumatic in-process measurement technology.
Werner Ankener graduated in mechanical engineering at the University of Kaiserslautern in 2018 and has been Research Assistant at the Institute of Materials Science and Engineering since then. Since 2018 he is working on a project of the Research Priority Program 2086 of DFG. His researches are focused on characterizing the surface layer morphology and fatigue behavior of hard turned AISI 52100.
Stephan Basten studied mechanical engineering with a focus on development and manufacturing methodology at the Technische Hochschule Mittelhessen University of Applied Sciences. Since August 2015 he is a research engineer at the Institute for Manufacturing Technology and Production Systems (FBK) focusing on machining technology.
Marek Smaga is head of the research group Metastability at the Institute of Materials Science and Engineering at TUK. His research focus on process-microstructure-mechanical and physical properties relationship of metastable and stable metallic material as well as on magneto-mechanical interaction in engineering materials.
Benjamin Kirsch studied mechanical engineering with a focus on manufacturing technology at TU Kaiserslautern. Since 2008 he is working at the Manufacturing Technology and Production Systems (FBK) and since 2014 he is chief engineer for manufacturing technology.
Prof. Dr.-Ing. Jörg Seewig studied electrical engineering at the Leibniz Universität Hannover. He gained his PhD in 2000 with a thesis on signal processing for surface roughness. Since 2008, he is chair of the institute for measurement and sensor technology at the Technische Universität Kaiserslautern. He is one of the German experts in Working Group 15 (Filtration) and Working Group 15 (Surface Texture) of ISO/TC213 Geometric Product Specification. He is project leader of various ISO documents e. g. ISO 16610-28, ISO 16610-31, ISO 16610-71 and ISO 21920-2.
Tilmann Beck is full professor and head of the Institute of Materials Science and Engineering at TUK since April 2014. He is chair of the DVM (German Association of Materials Testing and Research) working group “Thermo-Mechanical Fatigue” and speaker of the TUK Profile Area “Advanced Materials Engineering”. Since 2019 he is dean of TUK’s faculty of Mechanical and Process Engineering. Research Interests include process-microstructure-mechanical and physical properties relationship, isothermal and thermo-mechanical fatigue, additive manufacturing as well as ultrasonic welding.
Jan C. Aurich is professor and head of the Institute for Manufacturing Technology and Production Systems (FBK) at TU Kaiserslautern. His research interests lie in the areas of Micro- and Ultraprecision Machining, Manufacturing Technology, Additive Manufacturing, Digital Technologies for Production Systems and Sustainable Production. Professor Aurich is a fellow of the International Academy for Production Engineering (CIRP), member of the German Academic Association for Production Technology (WGP) and member of the National Academy for Science and Engineering (acatech).
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